Project Testing

After all the wiring and fitting completed, continuity test , provide supply , trib test done.. now it is the time to go to the final element, project test. Project will given up supply of a 240V and a load of 100Watts of bulb which is 6 bulbs overall total 600 watts. Once switch is turn on, all the bulbs is lights up.

Measuring total Amps in the circuit using clamp meter.

 

The output of the socket is 235V  as same as the input supply

Display read the meter well displaying the consumption power, value of kWh that had been used and the total value of the usage in Ringgit Malaysia

Hardware Development : Fitting and Wiring

After all the electrical stuff i had, i begin with  the box to place the circuit for Kwh meter.

then i place the distribution box next to the KwH box

 Wiring the connection for Main switch, Earth leakage circuit breaker, and Main circuit breaker. After done the wiring, do the continuity test again to check all the connection is good.

Drilling hole for fitting the bulb, switch and socket.

Fitting the bulb wire

Finalize the Hardware development .

Hardware Developement : contuinity test

To check the connectivity, i perform a continuity test, continuity test is  checking of an electric circuit to see if current flows (that it is in fact a complete circuit). A continuity test is performed by placing a small voltage (wired in series) across the chosen path. If electron flow is inhibited by broken conductors, damaged components, or excessive resistance, the circuit is "open".

Devices that can be used to perform continuity tests include multimeters which measure current and specialized continuity testers which are cheaper, more basic devices, generally with a simple light bulb that lights up when current flows.

An important application is the continuity test of a bundle of wires so as to find the two ends belonging to a particular one of these wires; there will be a negligible resistance between the "right" ends, and only between the "right" ends.

When the continuity test done, i give them load to prove the continuity test  achieved. 240v supply connection applied (life,neutral and ground). i use test pen to complete the task. once i touch at the end poit of test pen the light is on which means the connection is good at no leakage voltage.

Hardware Development : Electrical Appliance

Electrical Appliances

1. Main switch
2. Earth Leakage Current Breaker (ELCB)
3. Main Circuit Breaker (MCB)10A,16A
4. Electrical Deck Box
5. Bulb Holder
6. Bulb (100watts)
7. 2.5mm wiring cable
8. 1.5mm wiring cable
9. Switch box
10. socket box
11. wooden layout 

Software Development : Program the PIC

For software development i used MikroC, MikroElektronika C compiler for microchip PIC microcontrollers version : 8.0.0.0.

 

 I use basic C language for my project programming for PIC Microcontroller. after completed all of the program without any error( save file as .c), then compile all and proceed to burn HEX file to my PIC16F877A

1.  Import the HEX file
2. Reading the device and memory.

1.  verifying the device and memory
2. program was successful write into microcontroller.

The PIC Burner that i used to burn HEX file.

Circuit Design Part 7 : Soldering component

Soldering is defined as "the joining of metals by a fusion of alloys which have relatively low melting points". In other words, using a metal that has a low melting point to adhere the surfaces to be soldered together. Consider that soldering is more like gluing with molten metal, unlike welding where the base metals are actually melted and combined. Soldering is also a must have skill for all sorts of electrical and electronics work. It is also a skill that must be taught correctly and developed with practice.   

Soldering components onto a PCB involves preparing the surface, placing the components, and then soldering the joint.

Step 1: Surface Preparation:

 A clean surface is very important if you want a strong, low resistance solder joint. All surfaces to be soldered should be cleaned well.

Step 2: Component Placement:

After the component and board have been cleaned,its ready to place the components onto the board.

Step 3: Apply Heat:

Apply a very small amount of solder to the tip of the iron. This helps conduct the heat to the component and board, but it is not the solder that will make up the joint.

Step 4: Apply Solder To The Joint :

Once the component lead and solder pad has heated up, you are ready to apply solder. Touch the tip of the strand of solder to the component lead and solder pad.

Step 5: Inspect The Joint and Cleanup:

Once the surface of the pad is completely coated,the joint is made and should inspect it.

Circuit Design Part 6 : Drilling PCB board

Remove the coloured part that covered the cooper with Silicon Carbide Abrasive paper. Once it done proceed with drilling procedure.

 

Drilling with 0.8mm drill bits can be a bit tricky as it's easy to break the drill bits. Always hold the drill straight and do not bend it when the hole has started. Putting a soft block of wood under the PCB provides a good base to drill into.

1. Dry off the board and clean away the blue etch resist with brush. 
  2. Using a 0.8mm PCB drill bit drill out all of the component holes  
3. Some 1mm holes may need to be made for connectors, 3mm for corner fixings
4. Finally use a PCB rubber to clean the copper ready for soldering

So now PCB's finished and you can start soldering the components in. You should do this soon after you have cleaned the PCB (within 1 hour) as the copper soon oxidises and becomes hard to solder onto.